Mixing valve

ABSTRACT

A mixing valve includes a mixing chamber, a first flow control valve having a first flow control opening, and a second flow control valve having a second flow control opening. The first and second flow control openings each have a diameter of approximately six millimeters and the mixing valve has a flow coefficient of approximately 2.5 when both flow control valves are in a mid-open position.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

The present application claims the benefit of and priority to UnitedKingdom Patent Application No. 1211101.9, filed Jun. 22, 2012, andUnited Kingdom Patent Application No. 1211098.7, also filed Jun. 22,2012. The entire disclosures of United Kingdom Patent Application No.1211101.9 and United Kingdom Patent Application No. 1211098.7 (includingthe specification, drawings, claims and abstract), are incorporatedherein by reference. The present application also incorporates herein byreference (including the specification, drawings, claims and abstract),but does not claim priority to, U.S. patent application Ser. No.13/797,263, filed Mar. 12, 2013.

BACKGROUND

This application relates to valves, especially valves for plumbingfixtures, fittings and water supply systems and installations forwashing, showering, bathing and the like employing such plumbingfixtures and fittings. The invention has particular, but not exclusive,application to a mixer valve, especially a thermostatic mixer valve and,more particularly, to an electronically controlled thermostatic mixervalve. The invention also relates to a flow control valve and toapplications of such flow control valve in plumbing fixtures andfittings and parts thereof including, for example, a mixer valve.

A mixer valve receives a fluid flow from at least two sources andprovides an output comprising a mix or blend of the sources. Typically,mixer valves are used to control water flow in plumbing fixtures andfittings. In such fixtures and fittings, the mixer valve commonlyreceives a first input from a cold water supply and a second input froma hot water supply. The mixer valve includes controls that act tocontrol in what proportions the hot and cold supplies are mixed. Thus,the mixer valve mixes the hot and cold supplies in accordance with thesetting of its controls to achieve a desired water outlet temperature.

Manually operable thermostatic mixer valves typically include a valvemember that is manually adjustable to blend the hot and cold supplies inthe correct proportion to set a desired water outlet temperature and athermostat responsive to the water outlet temperature to adjust theposition of the valve member to maintain constant the selected wateroutlet temperature. The known manually operable thermostatic mixervalves may also provide control of the water outlet flow rate.

An example of such manually operable thermostatic mixer valves is shownin FIGS. 12 and 13. The mixer valve 101 is designed for mounting on awall or partition 102 within a shower enclosure and has elbow members103, 104 either side of a waisted body 105. The elbows 103, 104 areconnected to incoming supplies 106, 107 of hot and cold water enteringthe enclosure through the wall 102.

The body 105 houses a valve mechanism including a valve member that isaxially movable between hot and cold seats to control the relativeproportions of hot and cold water admitted to a mixing chamber. Thevalve member is manually adjusted to set the desired outlet watertemperature by a rotatable temperature control knob 110 at the front ofthe body 105.

The mixing chamber communicates with an outlet 108 in the body. Theoutlet 108 is shown arranged on the underside of the body 105 when thevalve 101 is installed on the wall 102 for connection to a flexible hosethat 109 delivers water to a handset. In other arrangements, the outletmay be arranged on the top of the body 105 when the valve 101 isinstalled on the wall 102 for connection to a rigid riser pipe thatdelivers water to a fixed overhead shower.

The valve mechanism includes a thermostat responsive to the watertemperature in the mixing chamber to adjust the position of the valvemember to maintain constant the selected water temperature. The valvefurther includes a rotatable flow control knob 111 mounted concentricwith the temperature control knob 110 to control and regulate the flowof water from off to fully open.

Such known valves 101 are relatively large (the inlets centers aretypically spaced 150 mm (6 inches) apart) and are often made of metaland therefore relatively heavy and expensive to manufacture.

Electronically controlled thermostatic mixer valves typically utilizemotors to control the movement of a valve member to blend the hot andcold supplies in the correct proportion to set a desired water outlettemperature and a temperature sensor responsive to the water outlettemperature to provide a signal to control circuitry to operate themotor to adjust the position of the valve member to maintain constantthe selected water outlet temperature.

An example of such electronically operable thermostatic mixer valves isshown in FIG. 14 and a mixer unit incorporating the mixer valve is shownin FIG. 15. The mixer valve 201 has a body 202 with inlets 203, 204 forconnection to supplies of hot and cold water and an outlet 205. The body202 houses a valve mechanism including a valve spool 206 having twoparts 206 a, 206 b provided with interlocking castellations that form aseries of slotted ports 207.

The inlets 203, 204 open to inlet chambers that surround the spool 206and the valve spool 206 is axially movable between a first end positionin which the ports 207 communicate with the inlet chamber connected tothe cold water supply corresponding to full cold and a second endposition in which the ports 207 communicate with the inlet chamberconnected to the hot water supply corresponding to full hot. Between theend positions, the ports 207 communicate with both inlet chambers and,adjusting the axial position of the spool 206 between the end positionsadjusts the relative proportions of hot and cold water flowing to theoutlet 205 and thus the water outlet temperature.

The spool 206 is axially adjustable under the control of a stepper motor208 that is coupled to the spool 206 by a drive mechanism including adrive rod 209. The stepper motor 208 is controlled by an electroniccontroller 210 (FIG. 15) arranged to receive signals from a userinterface (not shown) for selecting the desired water outlet temperatureand from a temperature sensor (not shown) mounted in the outlet 205 toadjust the position of the spool 206 to achieve and maintain the desiredoutlet water temperature.

Such known electronic mixer valves 201 are relatively large and onlycontrol the outlet water temperature not the flow rate. Consequently aseparate electronically operable flow control valve 211 is provided withassociated controls to start/stop water flow and control the flow rate.The flow control valve 211 has an inlet 212 connected to the outlet 205of the mixer valve 201. A valve member 213 engages a valve seat 214 toprevent flow of water from the inlet 212 to an outlet 215 in the closedposition of the valve.

The valve member 213 is urged away from the valve seat 214 to open theflow control valve 211 when a solenoid 217 is energized and openingmovement of the valve member 213 is controlled by a stepper motor 216via a drive rod 218 to control the flow rate of water delivered to theoutlet 215. The stepper motor 216 is controlled by the electroniccontroller 210 that receives signals from the user interface forselecting the desired flow rate of the outlet water and from a flow ratesensor mounted in the outlet to adjust the position of the valve member213 to achieve and maintain the desired outlet water flow rate.

The mixer valve 201 and separate flow control valve 211 are typicallycombined in a single unit 219 within a housing 220 for connection to theelectrical supply for the stepper motors. The large size of the units219 renders them unsuitable for mounting in a shower enclosure. As aresult, they are usually mounted remote from the shower enclosure, forexample in the ceiling above the shower enclosure with the outlet 215supplying connecting pipework to deliver outlet water to an overheadshower, a handset or other spray device within the shower enclosure andwith a wired or wireless connection from the user interface located inthe shower enclosure to the electronic controls for the mixer valve andflow control valve.

Due to the size and complexity of many parts of the mixer valve and flowcontrol valve that form the water way and come into contact with thewater, such parts are made of plastics materials to facilitatemanufacture and reduce the weight of the units. The use of plasticsmaterials however gives rise to a health risk from the presence ofharmful micro-organisms in the water supply, especially bacteria and inparticular legionella bacteria. The bacteria readily form a bio-film onsurfaces of the waterway in contact with the water that are made ofplastics material and the growth of bacteria forming the bio-film ispromoted in the warm water present in the waterways, especiallyimmediately after use while the water remaining in the valve is stillwarm and before it has cooled down. The large surface area of thewaterways in the known electronically controlled mixer valves thereforepresents a particular problem for effective control of bacteria toreduce the risk of users being infected by bacteria in the fine dropletsof water present in the shower area when showering and which can bereadily inhaled.

It is known to periodically flush the waterways with hot water for apre-determined period of time, typically at least 65° C. for at least 10minutes, to kill bacteria present on the surface of the waterways.However, if the water used is not hot enough or is not present for asufficient period of time the bacteria can survive and continue to grow.Also flushing with hot water may not remove bacteria present on thesurface of the waterway in trapped areas of the waterway that are notflushed by the hot water. This can be a further problem affecting theefficient removal of bacteria in complex waterways made of plasticsmaterials.

Hence a need exists for improved valves for plumbing fixtures, fittingsand water supply systems and installations for washing, showering,bathing and the like employing such plumbing fixtures and fittings.

SUMMARY

An exemplary embodiment relates to a mixing valve that includes a mixingchamber, a first flow control valve having a first flow control opening,and a second flow control valve having a second flow control opening.The first and second flow control openings each have a diameter ofapproximately six millimeters and the mixing valve has a flowcoefficient of approximately 2.5 when both flow control valves are in amid-open position.

Another exemplary embodiment relates to a mixing valve that includes amixing chamber, a first flow control valve having a first flow controlopening, and a second flow control valve having a second flow controlopening. The first and second flow control openings each have a diameterof approximately six millimeters and the mixing valve has a flow rate ofup to approximately 25 liters per minute at approximately 1 bar whenboth flow control valves are in a mid-open position.

BRIEF DESCRIPTION OF THE DRAWINGS

There now follows by way of example only a detailed description ofvarious exemplary embodiments disclosed in the present application, withreference to the accompanying drawings, in which:

FIG. 1 shows a view of an embodiment of a mixer valve;

FIG. 2 shows a cross-sectional view of the mixer valve shown in FIG. 1;

FIG. 3 shows a more detailed view of the flow control valves shown inFIG. 2;

FIG. 4 shows the mid-open position of the flow control valve shown inFIGS. 1 to 3;

FIG. 5 shows a perspective view of another embodiment of a mixer valve;

FIG. 6 shows a sectional view of the mixer valve of FIG. 5;

FIG. 7 shows a perspective view of another embodiment of a mixer valve;

FIG. 8a shows a plumbing fitting comprising a shower head incorporatingan embodiment of the mixer valve disclosed herein;

FIG. 8b shows a cut-away view of the shower head shown in FIG. 8ashowing the mixer valve therein;

FIG. 9a shows a plumbing fitting comprising a faucet incorporating anembodiment of the mixer valve disclosed herein;

FIG. 9b shows a cut away view of the faucet shown in FIG. 9a showing themixer valve therein;

FIG. 10 shows a further plumbing fitting comprising a shower headincorporating an embodiment of the mixer valve disclosed herein;

FIG. 11a shows a further embodiment of a plumbing fitting comprising abar mixer assembly incorporating an embodiment of the mixer valvedisclosed herein;

FIG. 11b shows a top view of the bar mixer assembly with the controlpanel removed;

FIG. 11c shows a detailed view of one of the flow control valves of thebar mixer assembly shown in FIG. 11 b;

FIG. 12 shows a front view of a prior art mixer valve;

FIG. 13 shows an underneath plan view of the prior art mixer valve ofFIG. 12;

FIG. 14 shows a side view of a prior art electronic mixer valve;

FIG. 15 shows a side view of a unit containing the prior art electronicmixer valve shown in FIG. 14; and

FIG. 16 shows a portion of a plumbing fixture that includes a userinterface for controlling the operation of the plumbing fixture.

DETAILED DESCRIPTION

According to an exemplary embodiment, a mixer valve includes a firstfluid inlet adapted to receive a first fluid, a second fluid inletadapted to receive a second fluid, a fluid outlet adapted to output thefirst fluid or the second fluid or a mixture thereof, and a first flowcontrol valve for controlling the flow of fluid from the first fluidinlet and a second flow control valve for controlling the flow of fluidfrom the second fluid inlet, each of the first and second flow controlvalves including a valve member assembly to control the fluid flowthrough the respective flow control valve, the valve member assembly andthe fluid inlet of each of the first and second flow control valvesbeing adapted and arranged such that, when in use, fluid flowing throughthe first flow control valve exerts substantially no net force on thevalve member assembly of the first flow control valve and fluid flowingthrough the second flow control valve exerts substantially no net forceon the valve member assembly of the second flow control valve.

According to another exemplary embodiment, there is provided a mixervalve for use in controlling mixing of two supplies of water havingdifferent temperatures comprising a cold water inlet adapted to receivea supply of cold water, a hot water inlet adapted to receive a supply ofhot water, a water outlet adapted to output cold water or hot water or amixture thereof, and a first flow control valve for controlling the flowof cold water from the cold water inlet to the water outlet and a secondflow control valve for controlling the flow of hot water from the hotwater inlet to the water outlet, each of the first and second flowcontrol valves including a valve inlet communicating with the associatedwater inlet, first and second, separate valve outlets communicating withthe water outlet and a valve member assembly to control the flow ofwater through the valve outlets, wherein each valve member assemblyincludes a first valve member adapted to engage with a first valve seatassociated with the first valve outlet in a closed position of the flowcontrol valve and a second valve member adapted to engage with a second,separate, valve seat associated with the second valve outlet in theclosed position of the flow control valve, wherein the first valvemember is arranged to be urged closed by water entering through thevalve inlet and the second valve member is arranged to be urged open bywater entering through the valve inlet such that, when in use, waterflowing through the first flow control valve exerts substantially no netforce on the valve member assembly of the first flow control valve andwater flowing through the second flow control valve exerts substantiallyno net force on the valve member assembly of the second flow controlvalve.

By the term “substantially no net force” we mean that the valve memberassembly is essentially “force balanced” with respect to the fluid flow.In other words, the force required to actuate the valve member assemblywhen controlling the valve is substantially independent of fluid flow.As a result, the actuating force can be reduced compared to valves wherethere is a significant imbalance of the forces due to fluid flow.

Reducing the actuating force to operate the valve member assembly mayenable the actuator to be made smaller than would otherwise be possiblewith potential cost and energy savings. Consequently, the mixer valveitself may be made smaller (because less power is required to operatethe valve member assembly) than would otherwise be possible in existingmixer valves.

By reducing the size of the mixer valve, the size of the waterwayswithin the mixer valve and thus the volume of water present in the mixervalve and the available surface area in contact with the water forbio-film to form and bacteria to grow can be reduced. Also theoccurrence of trapped areas in the waterways where water can collect andpromote growth of bacteria may be reduced. Furthermore, by reducing thesize of the mixer valve, it may be possible to manufacture the mixervalve, especially parts forming the waterways, from metal rather thanplastics. The use of metals can have further benefits for controllingthe growth of bacteria. Thus, bio-films form more readily on plasticsthan metal and bacteria are killed by contact with certain metals,especially metal alloys containing copper such as brass.

It will be understood that reducing the effect of fluid flow on thevalve member assembly is an important factor in reducing the size of themixer valve by reducing the actuating force required to operate thevalve member assembly. While it may therefore be desirable to eliminatethe effect of fluid flow on the valve member assembly altogether, it mayfor practical reasons not always be possible to achieve.

Accordingly, while the aim may be to reduce any imbalance of the forcesacting on the valve member assembly due to fluid flow when designing themixer valve, the benefits and advantages of reduced actuating force andthus reduced size (power) of the actuator and reduced size of the mixervalve may still be achieved to a large extent even if some imbalance ofthe forces acting on the valve member assembly due to fluid flow ispresent.

In some cases, it may even be desirable to have a small imbalance of theforces acting on the valve member assembly due to fluid flow. Forexample, a small imbalance of the forces may be utilized to hold thevalve member assembly closed without relying on the actuator. In thisway, it may not be necessary to provide power to the actuator when themixer valve is closed with consequential saving in energy costs.

Accordingly we intend the term “substantially no net force” to includenot only situations where there is no imbalance of the forces acting onthe valve member assembly due to fluid flow i.e. “fully force balanced”,but also situations where some imbalance of the forces is presentwhether by design or not provided that such imbalance does not result ina significant increase in the size (power) of the actuator.

The actual force required to operate the flow control valves when fullyforce balanced may depend on various factors including, but not limitedto (a) the size of the valve and/or of the valve member assembly, (b)the number, materials and arrangement of seals provided between thevalve members and the valve seats; and (c) the number, materials andarrangement of seals provided between the spool and the housing.

Thus, for a given valve, it may be that in some embodiments a level ofimbalance of up to ±10% of the actuating force when fully force balancedmay be present while in other embodiments a level of imbalance of up to±5% of the actuating force when fully force balanced may be present andin yet further embodiments a level of imbalance of the actuating forcewhen fully force balanced of up to ±2% may be present.

According to an exemplary embodiment, each flow control valve comprisesa valve inlet for receiving fluid from one of the first or second fluidinlets, the valve member assembly including a first valve member adaptedto engage with a first valve seat in a closed position of the flowcontrol valve and a second valve member adapted to engage with a second,separate, valve seat in the closed position of the flow control valve,the first valve member being arranged to be urged closed by fluidentering through the valve inlet and the second valve member beingarranged to be urged open by fluid entering through the valve inlet.

This is advantageous because, when in use, the force exerted by thefluid on each of the valve members can be balanced (as discussed herein)such that the actuating force to move the valve members from theirrespective valve seats can be reduced.

According to an exemplary embodiment, each valve inlet is locatedbetween the first valve member and the second valve member of each ofthe first and second flow control valves. For example, according to oneparticular exemplary embodiment, the valve inlet is configured to openinto an inlet chamber defined by a chamber wall having a first valveoutlet and a second valve outlet formed therein. The first valve seatmay be associated with the first valve outlet and the second valve seatmay be associated with the second valve outlet.

According to an exemplary embodiment, the mixer valve includes a mixingchamber that includes the fluid outlet, the mixing chamber beingarranged to receive fluid from the first and second fluid outlets of theflow control valves. This is advantageous as it has been found that ahigh flow rate can be achieved even when the valve is miniaturized(i.e., reduced in size).

According to an exemplary embodiment, the first and second valve outletsmay be of similar size. In some embodiments, the first and second valveoutlets may be the same size. This is advantageous as it been found toassist balancing the valve assemblies (as discussed herein).Furthermore, using two outlets we can achieve flow rates comparable withusing a single, larger outlet, thereby allowing the valve to beminiaturized (i.e. reduced in size).

According to an exemplary embodiment, the first valve member and secondvalve member are connected by a spool. In particular, the valve membersmay be fixedly mounted to the spool. According to an exemplaryembodiment, the spool may be coupled to an actuator which controls theposition of the valve members relative to their respective valve seats.According to an exemplary embodiment, the actuator comprises anelectrically-powered motor. The actuator may comprise a stepper motor.

It may be that the motor can be very low power as the double valvemember design ensures that the valve member assembly is substantiallybalanced against the force exerted by the fluid (as discussed herein).Thus, only a small actuation force is required. The stepper motor may beconnected to the spool such that rotational motion of the stepper motorcauses linear motion of the spool. Any suitable actuator for controllinglinear motion of the spool may be employed including, but not limitedto, linear actuators.

According to an exemplary embodiment, the first and second valve seatsmay be located within the valve outlets. For example, the valve seatsmay include a cylindrical bore portion of the valve outlets in which thevalve members are slidably received in the closed position. This isadvantageous as the spool carrying the valve members can be fitted fromone end of the valve by inserting the spool and valve members from oneend of the inlet chamber through one of the valve outlets to engage theother valve outlet at the opposite end of the inlet chamber.

According to a different exemplary embodiment, the first and secondvalve seats may be located at one end of the valve outlets. For example,the valve seats may include an end face of the valve outlets againstwhich the valve members seat in the closed position.

According to an exemplary embodiment, the first valve member may bereceived in the valve inlet chamber in an open position of the flowcontrol valve and the second valve member may be received in the mixingchamber in the open position of the flow control valve. In this way, thefirst valve member moves away from its valve seat to open the valveoutlet against the direction of fluid flow and the second valve membermoves away from its valve seat to open the valve outlet in the directionof fluid flow.

Thus fluid flow assists opening movement of the second valve member andopposes opening movement of the first valve member. The effect of thefluid flow on each valve member is reversed when moving the valvemembers towards their valve seats to close the valve outlets. The fluidforces acting on the valve members can be balanced (as discussed herein)when the valve outlets and valve members are matched, i.e. of similarsize, so that the actuator to operate the valve member assembly does nothave to overcome a significant force imbalance due to fluid flow bothwhen opening and closing the valve. This is advantageous as theactuation force is substantially independent of fluid flow and theactuator can be smaller than would otherwise be necessary.

According to an exemplary embodiment, the mixer valve comprises a valvehousing that houses the flow control valves. The housing may includeapertures that form the first fluid inlet, second fluid inlet, and fluidoutlet.

According to an exemplary embodiment, the housing may be made of metalor alloy, especially alloys containing copper such as brass to killharmful micro-organisms present in the fluid. An electrically poweredheating device may be provided for thermally disinfecting the mixervalve. The mixer valve may be disabled during a thermal disinfectioncycle to prevent discharge of fluid. The thermal disinfection cycle mayinclude a heating cycle to heat the housing to a temperature sufficientto disinfect waterways within the housing and optionally a cool downcycle to allow the housing and fluid contained in the valve to cool downafter the heating cycle.

According to an exemplary embodiment, the first and second flow controlvalves are connected to supplies of hot and cold water and arecontrolled in response to outlet water temperature and/or flow rate. Inone exemplary arrangement, a sensor device may be arranged to measurethe temperature and/or flow rate of the outlet water and the flowcontrol valves are controlled to achieve and maintain a user selectedoutlet water temperature and/or flow rate. In another exemplaryarrangement, a sensor device may be arranged to measure the temperatureof the supplies of hot and cold water and/or flow rate of the outletwater and the flow control valves are controlled to achieve and maintaina user selected outlet water temperature and/or flow rate.

According to another exemplary embodiment, a mixer valve includes afirst inlet for receiving a first fluid, a second inlet for receiving asecond fluid, and a mixing chamber having a fluid outlet for outputtingthe first fluid or the second fluid or a mixture thereof, the mixervalve including a first flow control valve for controlling the flow ofthe first fluid into the mixing chamber and a second flow control valve,separate from the first flow control valve, for controlling the flow ofthe second fluid into the mixing chamber, wherein at least the first orsecond flow control valve includes at least two, separate outlets intothe mixing chamber.

This is advantageous as the separate outlets ensure that a substantialflow rate can be maintained through the mixer valve even when it isminiaturized. The first inlet typically receives cold water from a coldwater supply and the second inlet typically receives hot water from ahot water supply.

According to an exemplary embodiment, at least the first or second flowcontrol valve includes a valve member assembly to control the flowthrough the control valve that is balanced (as discussed herein) suchthat fluid flowing through the control valve exerts substantially no netforce on the valve member assembly. This is advantageous as the forcerequired to actuate the valve member assembly when controlling the mixervalve is small. Accordingly, the actuator for moving the valve memberassembly and the mixer valve itself can be miniaturized (i.e. reduced insize).

According to an exemplary embodiment, both the first flow control valveand the second flow control valve each include at least two separateoutlets into the mixing chamber. According to an exemplary embodiment,each flow control valve is defined by an elongate valve inlet chamberhaving a valve inlet and two separate outlets formed at substantiallyopposite ends of the valve inlet chamber. Thus, each flow control valvecontrols the flow between the associated valve inlet chamber and themixing chamber.

According to an exemplary embodiment, each flow control valve includes avalve member assembly including a first valve member adapted to engagewith a first valve seat associated with a first of the two outlets and asecond valve member adapted to engage with a second, separate, valveseat associated with a second of the two outlets in the closed positionof the flow control valve.

The first valve member may be arranged to be urged closed by fluidentering the valve inlet chamber through the valve inlet and the secondvalve member may be arranged to be urged open by fluid entering thevalve inlet chamber through the valve inlet. Thus the first and secondflow control valves can be balanced (as discussed herein) due to thedual valve member design. The two outlets and two valve members ensure asubstantial flow rate can be achieved while ensuring the valve membersare fluid flow force balanced (as discussed herein) to aidminiaturization.

According to an exemplary embodiment, the first valve member and secondvalve member are connected by a spool. The valve members may be fixedlymounted to the spool. According to an exemplary embodiment, the spool isconnected to an actuator, which controls the position of the valvemembers relative to their respective valve seats. The actuator may be anelectrically powered motor, for example a stepper motor. The actuatormotor can be very low power as the double valve member design ensuresthat the valve is balanced (as discussed herein) against the forceexerted by the fluid. Thus, only a small actuation force is required.Accordingly, the stepper motor and thus the mixer valve itself can bevery small compared to prior art designs.

According to an exemplary embodiment, the first and second valve outletsmay be of similar size. According to an exemplary embodiment, the firstand second valve outlets can be the same size. According to an exemplaryembodiment, the first and second valve outlets may be axially aligned.

In some embodiments, the valve seats may be located within the valveoutlets. For example, the valve seats may include a cylindrical boreportion of the valve outlets in which the valve members are slidablyreceived in the closed position. This is advantageous as the spoolcarrying the valve members can be fitted from one end of the valve byinserting the spool and valve members from one end of the inlet chamberthrough one of the valve outlets to engage the other valve outlet at theopposite end of the inlet chamber.

In other embodiments, the valve seats may be located at one end of thevalve outlets. For example, the valve seats may include an end face ofthe valve outlets against which the valve members seat in the closedposition.

According to an exemplary embodiment, the first valve member may bereceived in the valve inlet chamber in an open position of the flowcontrol valve and the second valve member may be received in the mixingchamber in the open position of the flow control valve. In this way, thefirst valve member moves away from its valve seat to open the valveoutlet against the direction of fluid flow and the second valve membermoves away from its valve seat to open the valve outlet in the directionof fluid flow.

Thus fluid flow assists opening movement of the second valve member andopposes opening movement of the first valve member. The effect of thefluid flow on each valve member is reversed when moving the valvemembers towards their valve seats to close the valve outlets. The fluidforces acting on the valve members can be balanced (as discussed herein)when the valve outlets and valve members are matched, i.e. of similarsize, so that the actuator to operate the valve member assembly does nothave to overcome a significant force imbalance due to fluid flow bothwhen opening and closing the valve.

According to an exemplary embodiment, the mixer valve includes a housingthat houses the first and second flow control valves and includesapertures that form the first fluid inlet, second fluid inlet and fluidoutlet.

According to an exemplary embodiment, the housing may be made of metalor alloy, especially alloys containing copper such as brass to killharmful micro-organisms present in the fluid. An electrically poweredheating device may be provided for thermally disinfecting the mixervalve. The mixing valve may be disabled during a thermal disinfectioncycle to prevent discharge of fluid. The thermal disinfection cycle mayinclude a heating cycle to heat the housing to a temperature sufficientto disinfect waterways within the housing and optionally a cool downcycle to allow the housing and fluid contained in the valve to cool downafter the heating cycle.

According to an exemplary embodiment, the first and second flow controlvalves are connected to supplies of hot and cold water and arecontrolled in response to outlet water temperature and/or flow rate. Inone exemplary arrangement, a sensor device may be arranged to measurethe temperature and/or flow rate of the outlet water and the flowcontrol valves are controlled to achieve and maintain a user selectedoutlet water temperature and/or flow rate. In another exemplaryarrangement, a sensor device may be arranged to measure the temperatureof the supplies of hot and cold water and/or flow rate of the outletwater and the flow control valves are controlled to achieve and maintaina user selected outlet water temperature and/or flow rate.

According to another exemplary embodiment, a plumbing fitting may beconfigured to receive a mixer valve such as those described in thepresent application.

According to an exemplary embodiment, the plumbing fitting comprises afluid delivery device. According to an exemplary embodiment, the fluiddelivery device is a shower head. According to another exemplaryembodiment, the fluid delivery device is a faucet such as a bath tap,sink tap and basin tap. As the mixer valve can be easily miniaturized(i.e. reduced in size), it can be placed within plumbing fittings whereit was previously not possible to do so or doing so would have made thefitting large and/or heavy and/or cumbersome to use.

Thus, a shower system may simply comprise a shower head that receivesboth hot and cold water supplies through two conduits wherein the mixervalve is housed within the shower head and delivers water to an outletof the shower head. The mixer valve may be controlled via a controldevice such as a user interface which may be incorporated in the showerhead or provided separately and connected to the shower head via a wiredor wireless link. The interface may provide control signals to anelectronic controller that controls the actuators for the flow controlvalves according to user selected inputs of temperature and/or flow rateand/or outlet, for example where the shower system has multiple outlets.The electronic controller may receive inputs of the actual temperatureof the outlet water and/or the inlet water and/or flow rate fromappropriately positioned sensors and control the actuators for the flowcontrol valves in response thereto to achieve and maintain the userselected settings. The electronic controller may include amicroprocessor. The microprocessor may be programmable and may include amemory.

Likewise, a fluid delivery system may comprise a faucet that receivesboth hot and cold water supplies through two conduits wherein the mixervalve is housed within the faucet and delivers water to an outlet of thefaucet which may, in use, project over a bath, a sink or a basin. Themixer valve may be controlled via a control device such as a userinterface which may be incorporated in the faucet or provided separatelyand connected to the faucet via a wired or wireless link. The interfacemay provide control signals to an electronic controller that controlsthe actuators for the flow control valves according to user selectedinputs of temperature and/or flow rate and/or outlet, for example wherethe faucet has multiple outlets. The electronic controller may receiveinputs of the actual temperature of the outlet water and/or the inletwater and/or flow rate from appropriately positioned sensors and controlthe actuators for the flow control valves in response thereto to achieveand maintain the user selected settings. The electronic controller mayinclude a microprocessor. The microprocessor may be programmable and mayinclude a memory.

According to another exemplary embodiment, a shower head is configuredto receive a first fluid conduit and a second fluid conduit, wherein theshower head includes a mixer valve adapted to receive a first fluid fromthe first fluid conduit and a second fluid from the second fluid conduitand output the first fluid or the second fluid or a blend of the firstand second fluids to a shower head outlet. According to an exemplaryembodiment, the mixer valve may be such as those described in thepresent application.

According to an exemplary embodiment, the shower head includes a stem orbody portion to receive the first and second conduits and at least oneoutlet to discharge fluid received from the mixer valve. The stemportion may include a body having a duct therein for a fixed shower heador a handle having a duct therein for a moveable shower head. The ductmay carry first and second fluid conduits. The mixer valve may be suchas those described in the present application.

According to an exemplary embodiment, the shower head may be providedwith a spray head having a single outlet provided with a spray platehaving an array of holes for discharging water. The array of holes maybe configured to discharge water in any selected one of a plurality ofspray patterns.

According to another exemplary embodiment, the shower head is providedwith a spray head having a plurality of outlets and the spray head isadjustable to select any one of the outlets or a combination of outletsfor discharging water.

According to another exemplary embodiment, a fluid delivery device isconfigured to receive a first fluid conduit and a second fluid conduit,wherein the fluid delivery device includes a mixer valve adapted toreceive a first fluid from the first fluid conduit and a second fluidfrom the second fluid conduit and output the first fluid or the secondfluid or a blend of the first and second fluids to an outlet of thefluid delivery device. The mixer valve may be such as those described inthe present application

According to an exemplary embodiment, the fluid delivery device includesa body portion to receive the first and second conduits and an outlet todischarge fluid received from the mixer valve. The fluid delivery devicemay include a faucet. The faucet may comprise a tap selected from thegroup comprising a bath tap, a sink tap and a basin tap.

According to an exemplary embodiment, the body portion includes a baseportion and a stem portion (sometimes referred to as a “spout”) providedwith the outlet for discharging water. The mixer valve may be located inthe stem portion. This is advantageous because previous mixer tapsrequired the mixer valve to be located in the base of the faucet ratherthan the spout or even separate from the faucet altogether. The mixervalves as described herein can be miniaturized (i.e. reduced in size)such that it can be located in the stem portion, adjacent to, or withinthe outlet of the faucet. The faucet need not have controls at its baseas the faucet can simply comprise the stem portion.

The stem portion may be movable according to an exemplary embodiment.For example, it may be arranged to pivot about its base. Kitchen taps,for example, commonly have movable stem portions. The mixer valves asdescribed in the present application can be provided or mounted in themovable stem portion and not in a fixed valve base as in prior art tapdesigns.

The flow control valves disclosed in the present application may be usedindividually as flow control valves according to an exemplaryembodiment.

According to another exemplary embodiment, a flow control valve includesa valve inlet adapted to receive a fluid, a valve outlet adapted tooutput the fluid, the flow control valve including a valve memberassembly to control the fluid flow through the flow control valve,wherein the valve member assembly and the valve inlet are adapted andarranged such that, when in use, fluid flowing through the flow controlvalve exerts substantially no net force on the valve member assembly.

According to an exemplary embodiment, the valve member assemblycomprises a first valve member adapted to engage with a first valve seatin a closed position of the flow control valve and a second valve memberadapted to engage with a second, separate, valve seat in the closedposition of the flow control valve, wherein the first valve member isarranged to be urged closed by fluid entering through the valve inletand the second valve member is arranged to be urged open by fluidentering through the valve inlet.

This is advantageous because the force exerted by the fluid on each ofthe valve members can be balanced (as discussed herein) such that thevalve requires a small force to move the valve members from theirrespective valve seats.

According to an exemplary embodiment, the valve inlet is located betweenthe first valve member and the second valve member. The valve inlet mayopen into an inlet chamber defined by a chamber wall having a firstvalve outlet and a second valve outlet formed therein. The first valveseat may be associated with the first valve outlet and the second valveseat may be associated with the second valve seat.

According to an exemplary embodiment, the valve includes an outletchamber that includes the fluid outlet with the outlet chamber beingarranged to receive fluid from the first and second valve outlets of theinlet chamber. The first and second valve outlets may be of similarsize. The first and second valve outlets may be axially aligned, forexample at opposite ends of the inlet chamber.

According to an exemplary embodiment, the first valve member and secondvalve member are connected by a spool. In particular, the valve membersmay be fixedly mounted to the spool. According to an exemplaryembodiment, the spool is connected to an actuator which controls theposition of the valve members relative to their respective valve seats.

According to an exemplary embodiment, the actuator includes anelectrically-powered motor. The actuator may comprise a stepper motor.The motor can be very low power as the double valve member designensures that the valve is balanced (as discussed herein) against theforce exerted by the fluid. Thus, only a small actuation force isrequired. The stepper motor may be connected to the spool such thatrotational motion of the stepper motor causes linear motion of thespool. Any suitable actuator for controlling linear motion of the spoolmay be employed including, but not limited to, linear actuators.

According to an exemplary embodiment, the valve seats are located withinthe valve outlets. The valve seats may include a cylindrical boreportion of the valve outlets in which the valve members are slidablyreceived in the closed position.

According to an exemplary embodiment, the valve seats are located at oneend of the valve outlets. The valve seats may include an end face of thevalve outlets against which the valve members seat in the closedposition.

According to an exemplary embodiment, the first valve member is receivedin the valve inlet chamber in an open position of the flow control valveand the second valve member is received in the outlet chamber in theopen position of the flow control valve. In this way, the first valvemember moves away from its valve seat to open the valve outlet againstthe direction of fluid flow and the second valve member moves away fromits valve seat to open the valve outlet in the direction of fluid flow.

Thus fluid flow assists opening movement of the second valve member andopposes opening movement of the first valve member. The effect of thefluid flow on each valve member is reversed when moving the valvemembers towards their valve seats to close the valve outlets. The fluidforces acting on the valve members can be balanced (as discussed herein)when the valve outlets and valve members are matched, i.e. of similarsize, so that the actuator to operate the valve member assembly does nothave to overcome a significant force imbalance due to fluid flow bothwhen opening and closing the valve.

According to an exemplary embodiment, the flow control valve includes avalve housing that houses the valve member assembly. The housing mayhave apertures that form the fluid inlet and fluid outlet.

According to an exemplary embodiment, the housing may be made of metalor alloy, especially alloys containing copper such as brass to killharmful micro-organisms present in the fluid. An electrically poweredheating device may be provided for thermally disinfecting the flowcontrol valve. The flow control valve may be disabled during a thermaldisinfection cycle to prevent discharge of fluid. The thermaldisinfection cycle includes a heating cycle to heat the housing to atemperature sufficient to disinfect waterways within the housing and acool down cycle to allow the housing and fluid contained in the valve tocool down after the heating cycle.

According to another exemplary embodiment, a flow control valve includesan inlet for receiving a fluid, and an outlet chamber having an outletfor outputting the fluid, the flow control valve controlling the flow offluid into the outlet chamber, wherein the flow control valve includesat least two, separate valve outlets into the outlet chamber.

This is advantageous as the separate outlet apertures ensure that asubstantial flow rate can be maintained through the valve even when itis miniaturized (i.e. reduced in size).

According to an exemplary embodiment, the flow control valve includes anelongate inlet chamber having the inlet and two separate valve outletsformed at substantially opposite ends of the inlet chamber.

According to an exemplary embodiment, the flow control valve includes avalve member assembly to control the flow through the control valve thatis balanced (as discussed herein) such that fluid flowing through thecontrol valve exerts substantially no net force on the valve memberassembly. This is advantageous as the force required to actuate thevalve member assembly when controlling the valve is small. Accordingly,the actuator for moving the valve member assembly and the valve itselfcan be miniaturized (i.e. reduced in size).

According to an exemplary embodiment, the valve member assembly includesa first valve member adapted to engage with a first valve seatassociated with a first of the at least two valve outlets in a closedposition of the flow control valve and a second valve member adapted toengage with a second, separate, valve seat associated with a second ofthe at least two valve outlets in the closed position of the flowcontrol valve.

According to an exemplary embodiment, the first valve member is arrangedto be urged closed by fluid entering through the inlet chamber throughthe inlet and the second valve member is arranged to be urged open byfluid entering the inlet chamber through the inlet. Thus the flowcontrol valve can be balanced (as discussed herein) due to the dualvalve member design. The two outlets and two valve members ensure asubstantial flow rate can be achieved.

According to an exemplary embodiment, the valve inlet is located betweenthe first valve member and the second valve member. The valve inlet mayopen into the inlet chamber defined by a chamber wall in which the firstvalve outlet and the second valve outlet are formed.

According to an exemplary embodiment, the first valve member and secondvalve member are connected by a spool. The valve members may be fixedlymounted to the spool.

According to an exemplary embodiment, the spool is coupled to anactuator which controls the position of the valve members relative totheir respective valve seats. The actuator motor may comprise anelectrically powered motor and can be very low power as the double valvemember design ensures that the valve is balanced against the forceexerted by the fluid. Thus, only a small actuation force is required.Accordingly, a stepper motor can be used and thus the flow control valveitself can be very small compared to prior art designs.

According to an exemplary embodiment, the first and second valve outletsare of similar size. The first and second valve outlets may be axiallyaligned.

According to an exemplary embodiment, the valve seats are located withinthe valve outlets. For example, the valve seats may include acylindrical bore portion of the valve outlets in which the valve membersare slidably received in the closed position.

According to an exemplary embodiment, the valve seats are located at oneend of the valve outlets. For example, the valve seats may include anend face of the valve outlets against which the valve members seat inthe closed position.

According to an exemplary embodiment, the first valve member is receivedin the inlet chamber in an open position of the flow control valve andthe second valve member is received in the outlet chamber in the openposition of the flow control valve.

According to an exemplary embodiment, the flow control valve includes ahousing that includes apertures that form the fluid inlet and fluidoutlet.

According to an exemplary embodiment, the housing may be made of metalor alloy, especially alloys containing copper such as brass to killharmful micro-organisms present in the fluid. An electrically poweredheating device may be provided for thermally disinfecting the flowcontrol valve. The flow control valve may be disabled during a thermaldisinfection cycle to prevent discharge of fluid. The thermaldisinfection cycle may include a heating cycle to heat the housing to atemperature sufficient to disinfect waterways within the housing andoptionally a cool down cycle to allow the housing and fluid contained inthe valve to cool down after the heating cycle.

According to an exemplary embodiment, a method of controlling flow rateand/or temperature of outlet water from a mixer valve having first andsecond flow control valves is provided. The method includes connectingthe first flow control valve to a first water supply, connecting thesecond flow control valve to a second water supply, wherein the firstand second water supplies have different temperatures, configuring thefirst and second flow control valves so that an operating force toactuate the flow control valves is substantially independent of waterflow, and controlling the first and second flow control valvesseparately or in combination and outputting a flow of the first watersupply or the second water supply or a blend of the first and secondwater supplies having a desired flow rate and/or temperature.

According to another exemplary embodiment, there is provided a method ofcontrolling flow rate and/or temperature of outlet water from a mixervalve, the method including providing the mixer valve with a cold waterinlet, a hot water inlet, a water outlet, a first flow control valve forcontrolling flow of cold water from the cold water inlet, and a secondflow control valve for controlling flow of hot water from the hot waterinlet, providing each flow control valve with a valve inletcommunicating with the associated water inlet, two valve outletscommunicating with the water outlet and a valve member assembly tocontrol the flow of water through the respective flow control valve,connecting the cold water inlet to a cold water supply, connecting thehot water inlet to a hot water supply, wherein the cold and hot watersupplies have different temperatures, providing each valve memberassembly with a first valve member adapted to engage with a first valveseat in a closed position of the associated flow control valve and asecond valve member adapted to engage with a second, separate, valveseat in the closed position of the associated flow control valve sothat, the first valve member is arranged to be urged closed by waterentering through the valve inlet and the second valve member is arrangedto be urged open by water entering through the valve inlet such that,when in use, water flowing through the first flow control valve exertssubstantially no net force on the valve member assembly of the firstflow control valve and water flowing through the second flow controlvalve exerts substantially no net force on the valve member assembly ofthe second flow control valve so that an operating force to actuate thefirst and second flow control valves is substantially independent ofwater flow, and controlling the first and second flow control valvesseparately or in combination and outputting a flow of cold water or hotwater or a blend of the cold and hot water having a desired flow rateand/or temperature.

According to an exemplary embodiment, the first and second flow controlvalves each include a valve member assembly configured such that, whenin use, fluid flowing through the valve exerts substantially no netforce on the valve member assembly.

According to an exemplary embodiment, the first and second flow controlvalves each include a valve inlet chamber to receive water from theassociated water supply and having first and second outlets opening to amixing chamber.

According to an exemplary embodiment, the first and second outlets arearranged at opposite ends of the inlet chamber and are axially alignedand provide first and second valve seats for co-operating with first andsecond valve members connected to a common spool coupled to an actuatorfor adjusting the first and second valve members relative to the firstand second valve seats for controlling flow of water from the inletchamber to the outlet chamber.

According to an exemplary embodiment, in use, fluid flowing through eachflow control valve exerts a force on each valve member wherein the forceon the first valve member is substantially equal to and in the oppositedirection to the force exerted on the second valve member.

According to an exemplary embodiment, the outlet water is supplied to anoutlet of a water delivery device. The water delivery device may be ashower head or a faucet. The faucet may be selected from a bath tap, asink tap and a basin tap.

According to an exemplary embodiment, a method of controlling flow rateof outlet water from a flow control valve is provided. The methodincludes connecting the flow control valve to a water supply,configuring the flow control valve so that an operating force to actuatethe flow control valve is substantially independent of water flow, andcontrolling the flow control valve to output a flow of the water havinga desired flow rate.

According to an exemplary embodiment, the flow control valve includes avalve member assembly configured such that, when in use, fluid flowingthrough the valve exerts substantially no net force on the valve memberassembly.

According to an exemplary embodiment, the flow control valve includes avalve inlet chamber to receive water from the water supply and havingfirst and second outlets opening to an outlet chamber.

According to an exemplary embodiment, wherein the first and secondoutlets are arranged at opposite ends of the inlet chamber and areaxially aligned and provide first and second valve seats forco-operating with first and second valve members connected to a commonspool coupled to an actuator for adjusting the first and second valvemembers relative to the first and second valve seats for controllingflow of water from the inlet chamber to the outlet chamber.

According to an exemplary embodiment, in use, fluid flowing through theflow control valve exerts a force on each valve member wherein the forceon the first valve member is substantially equal to and in the oppositedirection to the force exerted on the second valve member.

According to an exemplary embodiment, the outlet water is supplied to anoutlet of a water delivery device. The water delivery device may be ashower head or a faucet. The faucet may be selected from a bath tap, asink tap and a basin tap.

Other features, benefits and advantages of the mixer valve and flowcontrol valve described herein will be apparent from the descriptionhereinafter of exemplary embodiments thereof and of the application ofthe mixer valve and flow control valve to plumbing fixture and fittingsand water supply systems and installations employing such plumbingfixtures and fittings. Such description is provided for the purpose ofdemonstrating the diverse ways in which the mixer valve and flow controlvalve can be configured and used and is not intended to be limiting onthe scope of the disclosure.

Turning now to the accompanying drawings, FIGS. 1 to 4 show anembodiment of a mixer valve for use in controlling the mixing of twosupplies of water having different temperatures (nominally hot and coldwater supplies) and outputting water having a desired temperature foruse. The valve may also control flow rate of the output water. The mixervalve may be incorporated into a plumbing fixture or fitting forwashing, showering, bathing or the like and water supply systems andinstallations employing such plumbing fixtures and fittings. Forexample, the mixer valve may be incorporated in a faucet for a basin,sink, shower bath or the like. The mixer valve may be incorporated in awater supply system or installation having one or more outlets forwashing, showering, bathing or the like. Each outlet may include afaucet incorporating the mixer valve. Alternatively, the mixer valve maybe incorporated in a fitting supplying more than one outlet. For examplemultiple shower heads may be supplied with water from one mixer valve.Other applications and uses of the mixer valve will be apparent to thoseskilled in the art from the description of the invention provided hereinand the invention extends to and includes all modifications and changeswithin the spirit and scope of the disclosure.

FIG. 1 shows the mixer valve 1 enclosed within a valve housing 2. Anaperture 3 in the housing 2 forms a first fluid inlet 4 for receiving afirst fluid (cold water in this embodiment). Similarly, as shown in FIG.2, the housing 2 includes a further aperture 5 that forms a second fluidinlet 6 for receiving a second fluid (hot water in this embodiment) anda still further aperture 7 that forms a fluid outlet 8 for outputtingthe first fluid or the second fluid or a mixture thereof.

FIGS. 2, 3 and 4 show the mixer valve 1 in cross section. The mixervalve 1 includes a first flow control valve 9 and a second flow controlvalve 10 located within a mixing chamber 11. The first flow controlvalve 9 controls the flow of fluid from the first fluid inlet 4 to themixing chamber 11. The second flow control valve 10 controls the flow offluid from the second fluid inlet 6 to the mixing chamber 11. The mixingchamber 11 provides a volume in which the first and second fluids canmix and directs the mixed fluid to the fluid outlet 8.

The first and second flow control valves 9, 10 are similar and arearranged side by side in parallel and on opposite sides of the mixingchamber 11. There follows a description of the construction andoperation of the first flow control valve 9 and the same referencenumerals have been used but with an additional apostrophe to identifysimilar features of the second flow control valve 10 such that theconstruction and operation of the second flow control valve 10 will beapparent and understood from the description of the first flow controlvalve 9.

The first flow control valve 9 includes a valve member assembly 12, avalve inlet chamber 13 and first and second valve outlets 14 a and 14 b.The inlet chamber 13 is substantially cylindrical. The first fluid inlet4 opens into the inlet chamber 13 through the side wall of the inletchamber 13 (the second inlet 6 opens into the valve inlet chamber 13′ ofthe second flow control valve 10 through the side wall of the inletchamber 13′).

The first valve outlet 14 a is arranged at one end of the inlet chamber13 and the second valve outlet 14 b is arranged at an opposed end of theinlet chamber 13. Each of the valve outlets 14 a and 14 b includes athrough bore with a cylindrical centre section 15 of reduced diameterrelative to the end sections 16, 17. The bore is tapered between thecentre section 15 and the end sections 16, 17. The valve outlets 14 aand 14 b are axially aligned and in this embodiment the centre sections15 of the outlets 14 a and 14 b are coaxial and have the same diameter.The valve member assembly 12 controls the flow of water through thefirst flow control valve 9 from the inlet chamber 13 to the mixingchamber 11.

The valve member assembly 12 comprises a first valve member 18 a adaptedto co-operate with the first valve outlet 14 a and a second valve member18 b adapted to co-operate with the second valve outlet 14 b to controlflow of water from the inlet chamber 13 to the mixing chamber 11. Thefirst and second valve members 18 a, 18 b are fixedly mounted on a spool19 such that they are held a predetermined distance apart. Thepredetermined distance corresponds to the distance between the first andsecond valve outlets 14 a, 14 b.

The first flow control valve 9 is shown in the full open position(maximum flow) in FIG. 2 and in the closed position (no flow) in FIG. 3(the second flow control valve 10 is shown in the closed position inFIG. 2 and in the full open position in FIG. 3). Both flow controlvalves 9, 10 are shown in a mid-open position in FIG. 4.

In the closed position, the first and second valve members 18 a, 18 bare received in the centre sections 15 of the first and second valveoutlets 14 a, 14 b and carry an elastomeric seal 20 a, 20 b that engagevalve seats provided by the centre section 15 of the first and secondvalve outlets 14 a, 14 b to seal the valve outlets 14 a, 14 b preventingflow of water from the inlet chamber 13 to the mixing chamber 11. Theelastomeric seal could be an O-ring carried by each valve member 18 a,18 b or could be a resilient portion over molded onto the outwardlyfacing surface of the valve member.

In the full open position, the first valve member 18 a is located withinthe inlet chamber 13 upstream of the associated valve outlet 14 a andthe second valve member 18 b is located outside the inlet chamber 13downstream of the associated valve seat 18 b in the mixing chamberwaterway. The first and second valve outlets 14 a, 14 b are configuredsuch that they present substantially the same area to the water flow.

The first fluid inlet 4 opens to the inlet chamber 13 between the firstand second valve outlets 14 a, 14 b. When opening the first flow controlvalve from the closed position, the force exerted by the water acts toresist opening movement of the first valve member 18 a and to assistopening movement of the second valve member 18 b. When closing the firstflow control valve from an open position, the force exerted by the wateracts to resist closing movement of the second valve member 18 b and toassist closing movement of the first valve member 18 a.

By configuring the valve outlets 14 a, 14 b to present substantially thesame area to the water flow and arranging the valve members 18 a, 18 bso that water acts on the valve members 18 a, 18 b in oppositedirections and with substantially the same force, the valve memberassembly 12 of the first flow control valve 9 is essentially balanced(as previously discussed). As a result, there is substantially no netforce on the valve member assembly 12 due to force exerted by the waterpressure when opening and closing the first flow control valve 9.

A first end of the spool 19 is received within a blind guide bore 21formed in the housing 2. A second, opposed end of the spool 19 extendsthrough an opening in the housing 2 and is connected to an actuator 22.The actuator 22 is connected to the housing 2. The actuator 22 isadapted to control the linear position of the spool 19 and thus theposition of the first and second valve members 18 a, 18 b with respectto the valve outlets 14 a, 14 b.

The actuator 22 comprises a stepper motor arranged to move the spool 19linearly in an axial direction. Any suitable actuator for controllinglinear motion of the spool may be employed in place of the stepper motorincluding, but not limited to, linear actuators. The actuator 22 isconnected to the spool 19 by a spool connector portion 23 coupled to thesecond end of the spool 19 that extends through an opening in thehousing 2. An elastomeric seal 24 engages the second end of the spool 19within the opening to prevent leakage of water from the mixing chamber11. The seal 24 could be an O-ring located in a groove in the housing 2.

The mixer valve 1 may include a controller (not shown) which providescontrol signals to the actuators 22, 22′ of the first and second flowcontrol valves 9, 10. The controller may also include a temperaturesensor and/or flow rate sensor to measure the temperature and/or flowrate of the water leaving the fluid outlet 8 or at any other relevantpoint in the mixer valve or external thereto. The signals from thesensor(s) may be used to control the actuator 22, 22′ of each flowcontrol valve 9, 10 to control the temperature and/or flow rate of thewater leaving the outlet 8. For example the signals may be used tomaintain a desired temperature and/or flow rate or to provide feedbackto the controller so that the water leaving the outlet 8 corresponds todesired settings despite changes in the water pressure and temperatureat the first fluid inlet 4 and/or second fluid inlet 6. The controllermay include an interface to receive settings input by a user. Wired orwireless communication may be provided between the controller, sensor(s)and interface.

Various methods of operating the actuator 22, 22′ of each flow controlvalve 9, 10 to control the temperature and/or flow rate of the waterleaving the outlet 8 are now discussed. These are examples only ofpossible methods of operation and are not intended to be exhaustive ofall possible ways in which the mixer valve 1 may be used to provide asource of outlet water having a desired temperature and/or flow rate.

Control to Output Cold Water or Hot Water

With the mixer valve 1 in the closed position, the first actuator 22 andsecond actuator 22′ position their respective spools 19 and 19′ suchthat the valve members 18 a, 18 b and 18 a′, 18 b′ of the first andsecond flow control valves 9, 10 are sealed against their respectivevalve seats 15 and 15′ to prevent flow of water to the outlet 8.

When only cold water is required by the user, the actuator 22 of thefirst flow control valve 9 is operated to open the first flow controlvalve 9 and the flow rate of cold water delivered to the outlet 8 iscontrolled by adjusting the position of the valve members 18 a, 18 brelative to the outlets 14 a, 14 b. The second flow control valveremains closed.

When only hot water is required by the user, the actuator 22′ of thesecond flow control valve 10 is operated to open the second flow controlvalve 10 and the flow rate of hot water delivered to the outlet 8 iscontrolled by adjusting the position of the valve members 18 a′, 18 b′relative to the outlets 14 a′, 14 b′. The first flow control valve 9remains closed.

Control to Output Blended Cold Water and Hot Water

With the mixer valve 1 in the closed position, the first actuator 22 andsecond actuator 22′ position their respective spools 19 and 19′ suchthat the valve members 18 a, 18 b and 18 a′, 18 b′ of the first andsecond flow control valves 9, 10 are sealed against their respectivevalve seats 15 and 15′ to prevent flow of water to the outlet 8.

When water having a temperature between full cold and full hot isrequired by the user, the actuators 22, 22′ of both flow control valves9, 10 are operated to open both flow control valves 9, 10 together todeliver a mixture of hot and cold water to the outlet 8. The temperatureand/or flow rate of the mixed water can, as an example, be adjusted asfollows:

Adjust Flow Control Valves Independently to Adjust Temperature and FlowRate

With both flow control valves 9, 10 open, the actuator 22 is operated tomove the valve member assembly 12 of the first flow control valve 9 toopen further the first flow control valve 9 and the actuator 22′ is keptstationary. The flow of cold water increases and the flow of hot waterremains the same resulting in an increase in flow rate and a decrease intemperature of the outlet water.

With both flow control valves 9, 10 open, the actuator 22 is operated tomove the valve member assembly 12 of the first flow control valve 9towards the closed position and the second actuator 22′ is keptstationary. The flow of cold water reduces and the flow of hot waterremains the same resulting in a decrease in flow rate and an increase intemperature of the outlet water.

With both flow control valves 9, 10 open, the actuator 22 is keptstationary and the actuator 22′ is operated to move the valve memberassembly 12′ of the second flow control valve 10 to open further theflow control valve 10. The flow of cold water remains the same and theflow of hot water increases resulting in an increase in flow rate and anincrease in temperature of the outlet water.

With both flow control valves 9, 10 open, the actuator 22 is keptstationary and the actuator 22′ is operated to move the valve memberassembly 12′ of the second flow control valve 10 towards the closedposition. The flow of cold water remains the same and the flow of hotwater reduces resulting in a decrease in flow rate and a decrease intemperature of the outlet water.

Adjust Flow Control Valves Together to Change Flow Rate and MaintainTemperature

With both flow control valves 9, 10 open, the temperature of the outletwater can be kept substantially constant while changing the flow rate byoperating the first and second actuators 22, 22′ together to move thevalve member assemblies 12, 12′ of both flow control valves 9, 10 in thesame direction by the same amount so that the ratio of cold water to hotwater delivered to the mixing chamber 11 remains substantially constantthus maintaining a constant temperature of the outlet water with achange in flow rate of the outlet water.

Thus, with both flow control valves 9, 10 open, if both valve memberassemblies 12, 12′ are moved to open further the flow control valves 9,10 the flow rate will increase, and if both valve member assemblies 12,12′ are moved towards the closed position the flow rate will decreasewithout changing the temperature of the outlet water.

Adjust Flow Control Valves Together to Change Temperature and MaintainFlow Rate

With both flow control valves 9, 10 open, the flow rate can be keptsubstantially constant while changing the temperature by operating thefirst and second actuators 22, 22′ together to move the valve memberassemblies 12, 12′ of both flow control valves 9, 10 in oppositedirections by the same amount so that the ratio of cold water to hotwater delivered to the mixing chamber 11 changes but the total volume ofwater remains the same thus maintaining a constant flow rate with achange in temperature of the outlet water.

Thus, with both flow control valves 9, 10 open, if the valve memberassembly 12 of the first flow control valve 9 is moved to open furtherthe first flow control valve 9 while simultaneously the valve memberassembly 12′ of the second flow control valve 10 is moved towards theclosed position, the flow rate will remain the same but the temperatureof the outlet water will decrease.

Similarly, with both flow control valves 9, 10 open, if the valve memberassembly 12′ of the second flow control valve 10 is moved to openfurther the second flow control valve 10 while simultaneously the valvemember assembly 12 of the first flow control valve 9 is moved towardsthe closed position, the flow rate will remain the same but thetemperature of the outlet water will increase.

As will be apparent from the description of the exemplary embodiment ofmixer valve 1 shown in FIGS. 1 to 4, the configuration of the valvemember assemblies 12, 12′ of the flow control valves controlling theflow of cold water and hot water to the mixing chamber is such that thevalve member assemblies 12, 12′ are essentially “force balanced” withrespect to the fluid flow. In other words, substantially no net force isexerted on the valve member assemblies 12, 12′ by the fluid flow and theactuating force to move the valve member assemblies 12, 12′ foroperating the flow control valves 9, 10 when controlling the mixer valve1 is substantially independent of fluid flow.

As a result, the actuating force can be reduced compared to valves wherethere is a significant imbalance of the forces due to fluid flow. Thus,the actuating force to move the valve member assemblies 12, 12′ only hasto overcome factors such as friction between the valve seats 15 and theseals 20 a, 20 b, 20 a′, 20 b′ on the valve members 18 a, 18 b, 18 a′,18 b′ and between the spools 19, 19′ and the bores 21, 21′ and betweenthe spool connector portions 23, 23′ and the seals 24, 24′.

By way of example only, in many water supply systems and installationsin the United Kingdom the water pressure is in the range 1 to 10 bar andis typically around 3 bar. If a single valve member is used to controlflow through an opening, there is a force imbalance across the valvemember due to fluid flow which has to be overcome by the actuating forcein addition to any other factors such as friction. For an opening have adiameter of 9 mm this force imbalance is approximately 60 Newtons at awater pressure of 10 bar and approximately 18 Newtons at a waterpressure of 3 bar.

By replacing a single opening with a diameter of 9 mm with two openingseach having a diameter of 6 mm we can achieve similar flow rates to thatprovided by the single opening of larger diameter and, by balancing theeffect of fluid flow on the valve members, we can reduce the size(power) of the stepper motors required to move the valve members as thestepper motors no longer have to overcome the force imbalance thatexists when using a single valve member.

Thus by employing force balanced valve assemblies, not only can the sizeof the flow control openings be reduced but the size of the steppermotors to drive the valve assemblies can also be reduced. This in turnalso enables the overall size of the mixer valve 1 to be reduced.

Again by way of example, using flow control openings having a diameterof 6 mm we can achieve a reduction in size of the mixer valve wherebythe housing 2 may have dimensions of 65 mm×30 mm×15 mm. By way ofcomparison prior art mixer valves as shown in FIGS. 12 and 13 typicallyhave dimensions of around 180 mm×130 mm×85 mm while prior art electronicmixer valves as shown in FIGS. 14 and 15 that control temperature onlyand require separate control of flow rate typically have dimensions ofaround 230 mm×210 mm×55 mm. According to an exemplary embodiment, amixing valve such as those disclosed herein may have a length dimension,a width dimension, and a thickness dimension, and the largest of thesedimensions may be no more than approximately 65 mm.

By reducing the size of the mixer valve 1, the size of the waterwayswithin the mixer valve 1 and thus the volume of water present in themixer valve 1 and the available surface area in contact with the waterfor bio-film to form and bacteria to grow can be reduced. Furthermore,by reducing the size of the mixer valve, it may be possible tomanufacture the mixer valve, especially parts of the housing 2 formingthe waterways and the flow control valves 9, 10 within the waterways,from metal rather than plastics. In particular, parts that come intocontact with the water within the mixer valve can be made of brass.Brass contains copper that kills present bacteria in the water therebyreducing and possibly eliminating the formation of bio-films on thesurface of the waterways and flow control valves 9, 10.

A further benefit of reducing the size of the waterways within the valveis that the occurrence of trapped areas where water may collect andallow bacteria to grow and/or form bio-films on surfaces within thevalve may be reduced. Also the waterways may be configured to promoteturbulent flow and high flow velocity through the valve. This is notonly desirable for mixing the hot and cold flows for accurate sensing ofthe temperature of the outlet water but also assists in preventingformation of bio-films on the exposed surfaces of the waterways withinthe valve and may even assist in removing any bio-films that are formed,for example as may occur when the valve is not in use, i.e. when thereis no flow of water through the valve, and bacteria present in the waterremaining in the valve from the previous use of the valve may grow andattach to the exposed surfaces.

To further reduce the health risk from bacteria present in the water, itmay be desirable to carry out a disinfection routine at regularintervals to kill and remove (or reduce to acceptable levels) anybacteria and bio-film within the valve. Such disinfection routine mayinvolve fully opening the flow control valve 10 connected to the supplyof hot water and passing water at an elevated temperature through thevalve 1 for sufficient time to kill and remove any bacteria and bio-filmwithin the valve. Typically this may involve passing water having atemperature of at least 65° C. through the valve for at least 10 minutesalthough this is by no way limiting and different routines withdifferent water temperatures and/or duration may be employed.

Other disinfection routines may be employed alongside or in place ofthermal disinfection with hot water. For example, FIGS. 5 and 6 show amodification to the mixer valve 1 of FIGS. 1 to 4 to include anelectrical heater 25 and like reference numerals are used to indicatecorresponding parts.

The water inlets 4, 6 are provided on one face 26 of the body 2 of thehousing and an electrical heater 25 is located in a bore 27 within thebody of the housing 2 on the opposite face 28 and is surrounded by athermally conductive potting compound 29 for transferring heat from theheater 25 to the metal body of the housing 2. The use of electricalheating for the disinfection routine is suitable as the valve 1 alreadyhas an electrical supply for operating the actuators.

The heater 25 may be employed in a thermal disinfection cycle to heatthe metal parts of the housing 2 and the flow control valves 9, 10within the housing 2 (one only shown in FIG. 6) that contact the waterto an elevated temperature sufficient to kill any bacteria present inthe water and/or any bio-film formed on the exposed surfaces of thewaterways within the valve. By reducing the size of the valve 1, thethermal mass of the metal parts to be heated may be significantlyreduced and a low power electrical heater (approximately 10 watt) may besufficient to heat the metal parts of the housing 2 and flow controlvalves 9, 10 to an elevated temperature of 70° C. to 80° C. for 5minutes which may be sufficient for this purpose.

An advantage of this method compared to the thermal disinfection withhot water is that all of the metal parts of the housing and the flowcontrol valves 9, 10 are heated whereas thermal disinfection with hotwater may not be effective in those areas that do not come into contactwith the hot water supply. A temperature sensor (not shown) such as athermistor may be provided to monitor the temperature during thedisinfection cycle and control the power input to the electrical heater25 to control the disinfection temperature and prevent overheating thehousing 2 and flow control valves 9, 10 which may damage any parts notmade of metal such as the seals.

The housing 2 is preferably insulated so that exposed external surfacesare not heated to a high temperature. In this way, the risk of a usertouching any part of the valve that has been heated to the elevatedtemperature used for the disinfection routine may be reduced andpossibly eliminated. Such insulation also improves the efficiency of thethermal disinfection cycle by reducing heat loss to the environment andmay allow use of a lower power heating element.

The valve 1 may be disabled during the disinfection cycle to preventdischarge of water from the outlet while the metal parts of housing 2and flow control valves 9, 10 are being heated during the disinfectioncycle and/or while they are cooling down after the disinfection cycle.Thus, operation of the mixer valve 1 may be prevented during thedisinfection cycle and for an interval of time after the disinfectioncycle is completed to allow the valve 1 and any water in the valve tocool down and prevent very hot water being discharged when the valve isnext used. In this way the risk of a user being scalded by very hotwater may be reduced and possibly eliminated.

The controller may respond to initiation of the disinfection cycle toprevent operation of the valve until it is safe. Thus, the temperaturesensor for controlling the electrical heater (or a separate sensor) mayprovide feedback of temperature to the controller so that the valve isnot operable until the metal parts of the housing 2 and flow controlvalves have cooled down to a safe temperature. Also the sensormonitoring the outlet water temperature (or a separate sensor) mayprovide feedback of temperature to the controller so that the valve isnot operable until the water in the valve has cooled down to a safetemperature. Any suitable form of electrical heating may be employed.

Referring now to FIG. 7, a mixer valve 1 is shown with a controller 55for controlling operation of the valve 1. The mixer valve 1 is similarto previous embodiments and like reference numerals are used to indicatesimilar parts. The controller 55 provides control signals to controlactuation of the actuators 22, 22′ of the first and second flow controlvalves (not visible) to adjust the positions of the valve memberassemblies (not visible) to control the flow rate and temperature of theoutlet water delivered to the outlet 8 as described previously.

The controller 55 may be an electronic controller with control circuitrythat may include a microprocessor or similar electronic controllermounted on a control panel 56 such as a printed circuit board. Thecontroller 55 may include an interface (not visible) to allow a user toselect a required flow rate and/or temperature of the outlet water. Theinterface may be a physical interface including one or more rotatableknobs or linear sliders or push buttons for selecting flow rate and/ortemperature. Alternatively, the interface may be a virtual interfacethat uses touch screen technology or the like. The interface may includea display for providing a visual indication of the flow rate and/ortemperature. The display may be a digital display of numerical valuesand/or visual display such as an array of lights. The controller 55receives the user's setting from the interface and sends control signalsto the actuators 22, 22′ to operate the flow control valves as describedin connection with previous embodiments to achieve the selectedtemperature and flow rate of the outlet water.

One example of an interface such as that described in the precedingparagraph is illustrated in FIG. 16. As illustrated, a plumbing fixture300 (e.g., a shower head, faucet, tub spout, etc.) that includes, forexample, an interface 310 (i.e., a user interface) in the form of atouchscreen that includes a display 320 (illustrated as showing acurrent temperature of water, such as the current temperature of waterexiting a plumbing fixture or other component), an on/off switch 330,and controls 332, 334, 336, and 338. The display can be configured todisplay any of a variety of information (e.g., the temperature indegrees Fahrenheit or degrees Celsius of hot and cold water entering amixing valve, the temperature of water leaving the mixing valve or of aspout or other structure, the flow rate of water leaving the mixingvalve or of a spout or other structure, or other values that may berelevant to the user's use of the interface in conjunction with theplumbing fixtures and fittings described in the present application).The on/off switch may be used to switch on and off the display of theinterface and/or may be used to turn on and off the flow of water orother fluid from the plumbing fixture, plumbing fitting, etc. Thecontrols 332, 334, 336, and 338 may be configured to allow a user toadjust the flow rate and/or temperature of the water. For example,controls 332 and 334 may be configured to allow a user to increase ordecrease temperature of water provided by a faucet, and controls 336,338 may allow the user to adjust the flow rate of that water. Accordingto another exemplary embodiment, controls 332 and 334 may be configuredto allow a user to increase or decrease the flow rate of the water andcontrols 336, 338 may allow the user to adjust the temperature of thatwater. Of course, according to other exemplary embodiments, an interfacemay include only one of temperature or flow control (e.g., onlytemperature control, only flow control) such that the other oftemperature or flow control may be provided by other components (e.g.,faucet handle(s), remote controllers, etc.). According to otherexemplary embodiments, the interface may include mechanical switchesand/or knobs instead of utilizing a interface. Also, in addition to thefunctions described above, the interface can include controls for otherfeatures (e.g., to initiate, stop, and control a cleaning ordisinfecting cycle for the mixing valve and/or plumbing fixture, asdescribed herein, for example, with respect to an embodiment in whichthe mixing valve includes a heating element for heating a body of themixing valve).

According to various exemplary embodiments, the interface 310 may beprovided in any desired location (e.g., on or coupled to a surface, suchas an outer surface, of the plumbing fixture (e.g., on a spout orescutcheon of a faucet, etc.), at a location remote from the plumbingfixture and in communication with the mixing valve, which may be withinthe plumbing fixture our outside of the plumbing fixture, etc.). Forexample, examples of possible locations are shown, for example, in FIGS.9a-9b and FIG. 11a , although it should be understood that otherlocations are possible according to other exemplary embodiments. Forexample, the portion of the plumbing fixture 300 illustrated in FIG. 16may be a handle of a shower head such as the shower head 50 shown inFIG. 8a , which would allow a user to use one hand both to manipulatethe shower head and to control the flow rate and/or temperature (e.g.,the interface may be accessible on an outer surface of the stem orhandle of the shower head or on a spray head of the shower head).According to another exemplary embodiment, the portion of the plumbingfixture 300 illustrated in FIG. 16 may be a spout or other component ofa faucet. According to another exemplary embodiment, the interface maybe positioned remotely from the plumbing fixture but may be configuredto communicate with a controller to control the mixing valve for theplumbing fixture that is located within the plumbing fixture.

The controller 55 may be programmable and may include a memory forstoring different settings of temperature and/or flow rate of the outletwater that may be set via the interface and selected by a user via theinterface. The controller 55 may allow selection of a disinfection cycleand may collect and store details of the disinfection cycle. Forexample, in plumbing fixtures and fittings and water supply systems andinstallations that require regular disinfection, the memory may recordwhen the disinfection cycle is carried out and the temperature of theoutlet water and the duration of the disinfection cycle which may beused to check that the disinfection routine has been carried out and hasbeen successful.

The interface may be incorporated into the plumbing fixture or fitting.Alternatively or additionally, the interface may be incorporated into aremote control that communicates with the controller 55 via a wired orwireless connection. For example, where the mixer valve 1 isincorporated in a plumbing fixture or fitting that, in use, is out ofreach of the user, the controller 55 may receive control signals via awired or wireless link from an interface mounted remotely from the mixervalve 1. In one form of wireless link, the interface may include awireless transmitter and the controller may include a wireless receiverto receive control signals, for example radio frequency signals,representative of a user's selected input via the interface.

By reducing the size of the mixer valve 1, the mixer valve 1 may beconfigured for supplying water for a range of different applicationsincluding hand washing, showering and bathing. Thus mixer valves forsupplying water for hand washing may typically be required to have aflow coefficient (C-value) of 0.5 to 1.0 corresponding to flow rates of5 to 10 liters per minute at a pressure of 1 bar, while mixer valvessupplying water for showering may typically be required to have a flowcoefficient of 1.0 to 3.0 corresponding to flow rates of 10 to 30 litersper minute at a pressure of 1 bar and mixer valves for supplying waterfor bath filling may typically be required to have a flow coefficient of3.0 to 5.0 corresponding to flow rates of 30 to 50 liters per minute at1 bar.

We have found that using flow control openings have a diameter of 6 mmwe can achieve a flow coefficient (C-value) of around 2.5 correspondingto a flow rate of 25 liters per minute at 1 bar when both flow controlvalves 9, 10 are in the mid-open position (FIG. 4). In this way, themixer valve 1 can meet the flow requirements for hand washing, showeringand bath filling. According to another exemplary embodiment, the flowcoefficient (C-value) may be up to around 2.5 corresponding to a flowrate of up to around 25 liters per minute at approximately 1 bar whenboth flow control valves 9, 10 are in the mid-open position

The flow rates for showering are provided when both flow control valves9, 10 are opened to the mid-open position (FIG. 4) and controllingtemperature without changing flow by reducing flow of one supply andincreasing flow of the other supply by the same amount or controllingflow without changing temperature by either reducing or increasing flowof both supplies by the same amount. Flow rates for hand washing may beachieved by opening both flow control valves 9, 10 less than themid-open position (FIG. 4) and controlling temperature and/or flow rateas for showering. Higher flow rates for bath filling can be achieved byfully opening both flow control valves 9, 10 and controlling temperatureby reducing flow of the hot or cold water as necessary.

These flow rates and dimensions are provided by way of non-limitingexample and it will be understood that different flow rates anddimensions may be employed where appropriate for the intendedapplication of the mixer valve.

Various control routines may be employed for operating the mixer valve 1depending on the application. Routines for showering and bath fillingare now described. These are examples only of possible routines and arenot intended to be exhaustive of all possible routines which may be usedwhen operating the mixer valve 1.

Routine for Showering

The valve member assemblies 12, 12′ of the first and second flow controlvalves 9 and 10 are both moved simultaneously and equally to themid-open position (50% actuator travel) shown in FIG. 4 by theirrespective actuators 22, 22′ to provide a nominal flow rate.

To change the flow rate without changing the temperature of the outletwater, both valve member assemblies 12, 12′ are simultaneously movedfrom the mid-open position (FIG. 4) in the same direction either towardsthe closed position to reduce flow rate or towards the open position toincrease flow rate while maintaining the ratio of hot and cold water tokeep the temperature of the outlet water constant.

Further changes to increase or decrease flow from any adjusted positionwithout changing the temperature of the outlet water can be made insimilar manner.

To change the outlet water temperature without changing the flow ratefrom the nominal flow (50% of actuators travel position) starting point,the valve assemblies 12, 12′ are simultaneously moved in oppositedirections to increase one flow whilst simultaneously reducing the otherflow by an equal amount. By operating the first and second flow controlvalves 9, 10 in this way, the ratio of the hot and cold water is changedbut the total flow remains the same so that the temperature of theoutlet water can be adjusted without substantially affecting the flowrate.

Both temperature and flow rate can be adjusted in use by a combinationof movement of the valve member assemblies to change the flow rate andthe temperature and/or to maintain a selected flow rate or temperature.

Routine for Bath Filling

The valve member assemblies 12, 12′ of the first and second flow controlvalves 9, 10 are both moved to the fully open positions (100% actuatortravel) to achieve the maximum flow rate.

Temperature is then controlled by reducing the flow of hot water if thetemperature of the outlet water needs to be reduced by moving the valvemember assembly 12′ of the second flow control valve 10 towards theclosed position or by reducing the flow of cold water if the temperatureof the outlet water needs to be increased by moving the valve memberassembly 12 of the first flow control valve 9 towards the closedposition.

Although such adjustment changes the flow rate as well as thetemperature of the outlet water, such change is acceptable in thecontext of bath filling where the user is typically not exposed directlyto the flow of water from the outlet as is usually the case whenshowering where changes to flow and temperature are readily detected andgreater control is required, particularly to reduce the risk of scaldingby very hot water.

By reducing the size of the mixer valve 1, it may be possible to employthe mixer valve 1 in situations where it has not previously beenpossible to use existing mixer valves. In particular, the small size ofthe mixer valve 1 as discussed herein opens up the possibility ofincorporating the mixer valve into a wide range of plumbing fixtures andfittings that could not incorporate existing mixer valves due to theirsize and other constraints on the design and installation of suchplumbing fixtures and fittings.

The mixer valve 1 may also be used to replace mixer valves employed inexisting plumbing fixtures and fittings. Here the small size of themixer valve 1 may allow the size of such existing plumbing fixtures andfittings to be reduced and/or the shape to be altered.

Thus, the mixer valve 1 increases the freedom of designers whendesigning plumbing fixtures and fittings and water supply systems andinstallations incorporating such plumbing fixtures and fittings thatincorporate the mixer valve 1. Various examples of plumbing fixture andfittings incorporating the mixer valve 1 are now described. These areexamples only of possible applications of the mixer valve 1 and are notintended to be exhaustive of all possible applications in which themixer valve 1 may be incorporated in a plumbing fixture or fitting.

Referring to FIGS. 8a and 8b , an embodiment of a plumbing fitting 50comprising a fluid delivery device such as a shower head incorporating amixer valve 1 is shown. The mixer valve 1 is similar to previousembodiments and like reference numerals are used to indicatecorresponding parts.

The shower head 50 comprises a moveable handset and includes a stem 51that can be inserted into a shower head dock within a shower enclosure(not shown). The shower head 50 could alternatively be a fixed showerhead that is arranged to be fixed to and project from a wall.

The shower head 50 includes a spray head 53 that provides a plurality ofoutlets for discharge of water in use to provide a variety of differentspray patterns. In one arrangement, the spray head 53 has outlets inopposite sides and optionally on one or more side edges. The spray head53 can rotate within a substantially circular spray head mount 58 aboutdiametrically opposed pivots 59 to select an outlet for use.

According to other exemplary embodiments, other types of spray heads maybe used, including those that are configured to provide only a singlespray pattern and those that operate differently than the spray head 53shown in FIGS. 8a and 8b to provide multiple spray patterns.

The shower head stem 51 receives the mixer valve 1 together with thecontroller 55. The stem 51 includes two conduits—a cold water supplyconduit 54 and a hot water supply conduit (not visible). The cold waterconduit 54 connects to the first fluid inlet 4 and the hot water conduitconnects to the second fluid inlet (not shown) of the mixer valve 1. Thefluid outlet 8 of the mixer valve 1 is connected to the spray head 53 byan outlet conduit 56. The outlet conduit 56 extends through the sprayhead mount 58 and enters the spray head 53 through the pivots 59.

The controller 55 provides control signals to the mixer valve 1 forcontrolling the flow rate and temperature of the outlet water deliveredto the spray head 53 according to the user selection via the interface(not visible). The interface may be arranged on the stem 51 to allow auser to select the flow rate and temperature of the outlet water theywish. The interface may be a physical interface including one or morerotatable knobs or linear sliders or push buttons for selecting flowrate and/or temperature. Alternatively, the interface may be a virtualinterface that uses touch screen technology or the like. The interfacemay include a display for providing a visual indication of the flow rateand/or temperature. The display may be a digital display of numericalvalues and/or visual display such as an array of lights.

In other embodiments, the interface may be incorporated into a remotecontrol that communicates with the controller 55 via a wired or wirelesslink. Thus, if the shower head 50 is of fixed type, then the controller55 may receive control signals from an interface mounted remotely fromthe shower head 50.

Referring now to FIGS. 9a and 9b , an embodiment of a plumbing fittingcomprising a fluid delivery device such as a faucet 60 incorporating amixer valve 1 is shown. The mixer valve 1 is similar to previousembodiments and like reference numerals are used to indicatecorresponding parts.

The faucet 60 may be in the form of a tap and includes a base 61 bywhich it is secured to a support surface such as a sink or worktop (suchas kitchen or bathroom worktop). The faucet 60 includes a perforatedplate 63 that provides an outlet for the water for use. The faucet 60receives the mixer valve 1 together with the controller 55. The faucet60 has a stem portion (sometimes referred to as a “spout”) and twoconduits—a cold water supply conduit 64 and a hot water supply conduit65. The cold water conduit 64 connects to the first fluid inlet 4 andthe hot water supply connects to the second fluid inlet (not visible) ofthe mixer valve 1. The fluid outlet 8 of the mixer valve 1 is connectedto the plate 63 by an outlet conduit 66.

The controller (not shown) provides control signals to the mixer valve 1for controlling the flow rate and temperature of the outlet waterdelivered to the plate 63 according to the user selection via aninterface 67 on the base 61 to allow a user to select the flow rate andtemperature they wish. The interface 67 includes a touch sensitive panel67 a for inputting settings and a display 69 b which shows the watertemperature. It will, be appreciated that the interface 67 can be of anysuitable form for receiving user inputs for controlling the mixer valve1. It should also be understood that similar types of user interfacesmay be employed either as part of or adjacent to other plumbing fixturesand fitting discussed herein (e.g., on or adjacent to a shower head or astem thereof, on or adjacent to a tub spout, etc.).

Conventional faucets require a valve base that is secured to the supportsurface and the spout then extends from the valve base to channel thewater to where it needs to be dispensed. The present embodiment isadvantageous as the mixer valve, due to its ability to be miniaturized(i.e. reduced in size), can be incorporated into the spout without theneed for the valve base. Also the rectangular shape of the housing 2provides the designer with the opportunity to employ differentconfigurations for the stem portion (spout) of the faucet.

Referring now to FIG. 10, an embodiment of a plumbing fitting comprisinga fluid delivery device such as a fixed shower head 70 incorporating amixer valve 1 is shown. The mixer valve 1 is similar to previousembodiments and like reference numerals are used to indicatecorresponding parts.

The fixed shower head 70 includes a base 71 by which it is secured to awall or similar support surface within a shower enclosure (not shown).The shower head 70 includes a perforated plate 72 that provides anoutlet for the water in use. The shower head 70 receives the mixer valve1 together with the controller 55. The shower head 70 has two conduits—acold water supply conduit 73 and a hot water supply conduit 74. The coldwater supply conduit 73 is connected to the first fluid inlet (notvisible) and the hot water supply conduit 74 is connected to the secondfluid inlet (not visible) of the mixer valve 1.

The mixer valve 1 is similar to the embodiment shown in FIGS. 8a and 8bexcept that the controller 55 is mounted within the shower head 70differently such that the supply conduits 73 and 74 pass between themixer valve 1 and the controller 55. The fluid outlet 8 of the mixervalve 1 is connected to the plate 72 by an outlet conduit 76.

The controller 55 provides control signals to the mixer valve 1 forcontrolling the flow rate and temperature of the outlet water deliveredto the plate 72 according to the user selection via a remote interface(not shown) allowing a user to select the flow rate and temperature theywish. It will be appreciated that the interface can be of any suitableform such as the interfaces disclosed herein for receiving user inputsfor controlling the mixer valve 1 and the controller 55 may be arrangedto receive control signals from the interface by a wired or wirelesslink for controlling the actuators 22, 22′.

Referring now to FIGS. 11a, 11b and 11c , an embodiment of a plumbingfitting comprising a shower valve 40 of the bar mixer type thatincorporates an embodiment of the mixer valve 1 described herein isshown.

The shower valve 40 comprises a cold water inlet 41, a hot water inlet42 and a blended water outlet 43. The outlet is connected to a flexibleshower hose 44 that leads to a shower head (not shown) or the like. Theshower valve 40 includes a control panel 45 which controls the mixervalve 1. The control panel 45 includes controls 45 a for switching theshower on and off, setting the flow rate and the temperature of theoutlet water and also a temperature display 45 b to display thetemperature of the outlet water. The controls 45 a may include aninterface such as the interfaces disclosed herein.

In this embodiment, the mixing chamber 11 includes an elongate structureformed by a conduit with the first flow control valve 9 at one end ofthe conduit and the second flow control valve 10 at the other, opposedend of the conduit. The valve outlet 43 is formed in the conduit inbetween the first and second flow control valves 9, 10.

The flow control valves 9, 10 are similar to those described above inrelation to the embodiment of FIGS. 1 to 4 and like reference numeralsare used to indicate corresponding parts. The first flow control valve 9is shown in FIG. 11c and the following description of the first flowcontrol valve 9 also applies to the second flow control valve 10.

In this embodiment, the flow control valve 9 has a valve member assembly12 with valve members 18 a, 18 b mounted on a spool 19 connected to anactuator 22. The valve members 18 a, 18 b carry an elastomeric seal 20a, 20 b that faces in a longitudinal and radial direction. Rather thanbeing received in the centre section of the valve outlets 14 a, 14 b inthe closed position as in the embodiment of FIGS. 1 to 4, the valvemembers 18 a, 18 b are arranged to engage end sections of the valveoutlets 14 a, 14 b that provide the valve seats in the closed positionshown in FIG. 11 c.

The valve member 18 a is disposed within the inlet chamber 13 andengages end section 16 of the valve outlet 14 a and the valve member 18b is arranged in the mixing chamber 11 and engages the end section 17 ofthe valve outlet 14 b. The valve inlet chamber 13 receives the waterfrom the inlet 4 and the valve members 18 a, 18 b are movable under thecontrol of the actuator 22 to open the flow control valve and controlthe flow of water from the valve chamber 13 into the mixing chamber 11in similar manner to the embodiment of FIGS. 1 to 4. The mixing chamber11 receives water from one or both flow control valves 9, 10 accordingto the operating routine of the mixer valve 1 as described in connectionwith FIGS. 1 to 4 and the water leaves the mixing chamber 11 via outlet43 for use.

The embodiments described above relate to mixer valves. However, theflow control valves 9, 10 could be used individually to control fluidflow. As an example, the control valve 9 shown in FIG. 11c could beemployed separately from the flow control valve 10 in any applicationwhere it is desired to control the flow rate of a water supply.

In such application, the mixing chamber 11 of the shower valve 40 shownin FIG. 11b is replaced with an outlet chamber which directs the flowfrom the outlets 14 a, 14 b of the flow control valve 9 to an outlet(not shown) for the intended application. The flow control valve 9operates to control flow rate in similar manner to previous embodiments.Similarly the flow control valves 9, 10 of other embodiments may beemployed separately to control flow rate.

One application for such a flow control valve could be in aninstantaneous water heater of the type in which a supply of water isheated as it passes through a heater tank to provide a source of hotwater on demand. In such instantaneous water heaters (sometimes referredto as continuous flow water heaters), for a given power input to theheater tank, the temperature of the outlet water is determined by theflow rate of the water through the heater tank and control of flow ratemay be used to achieve and maintain a selected outlet water temperature.One application for such water heaters is in an electric shower tosupply water to one or more shower outlets such as a handset or fixedshower handset. Other applications of the flow control valve will beapparent to those skilled in the art.

It will be appreciated that while the embodiments of the mixer valve andthe flow control valve described herein are shown as being incorporatedinto plumbing fittings, they have wider application. For example, due tothe valve's ability to be miniaturized (i.e. reduced in size) whilemaintaining a high flow rate for its size it may have advantageous usesin process control valves, pneumatic and hydraulic systems, medicalequipment or in automotive components or other components where controlof flow rate of a fluid and/or mixing of two fluids having differentcharacteristics is required. Thus, mixing fluids may not be limited tofluids having different temperatures.

As utilized herein, the terms “approximately,” “about,” “around,”“substantially,” and similar terms are intended to have a broad meaningin harmony with the common and accepted usage by those of ordinary skillin the art to which the subject matter of this disclosure pertains. Itshould be understood by those of skill in the art who review thisdisclosure that these terms are intended to allow a description ofcertain features described and claimed without restricting the scope ofthese features to the precise numerical ranges provided. Accordingly,these terms should be interpreted as indicating that insubstantial orinconsequential modifications or alterations of the subject matterdescribed and claimed are considered to be within the scope of theinvention as recited in the appended claims.

It should be noted that the term “exemplary” as used herein to describevarious embodiments is intended to indicate that such embodiments arepossible examples, representations, and/or illustrations of possibleembodiments (and such term is not intended to connote that suchembodiments are necessarily extraordinary or superlative examples).

The terms “coupled,” “connected,” and the like as used herein mean thejoining of two members directly or indirectly to one another. Suchjoining may be stationary (e.g., permanent) or moveable (e.g., removableor releasable). Such joining may be achieved with the two members or thetwo members and any additional intermediate members being integrallyformed as a single unitary body with one another or with the two membersor the two members and any additional intermediate members beingattached to one another.

References herein to the positions of elements (e.g., “top,” “bottom,”“above,” “below,” etc.) are merely used to describe the orientation ofvarious elements in the FIGURES. It should be noted that the orientationof various elements may differ according to other exemplary embodiments,and that such variations are intended to be encompassed by the presentdisclosure.

It is important to note that the construction and arrangement of themixer valves and related assemblies as shown in the various exemplaryembodiments is illustrative only. Although only a few embodiments havebeen described in detail in this disclosure, those skilled in the artwho review this disclosure will readily appreciate that manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter described herein. Forexample, elements shown as integrally formed may be constructed ofmultiple parts or elements, the position of elements may be reversed orotherwise varied, and the nature or number of discrete elements orpositions may be altered or varied. The order or sequence of any processor method steps may be varied or re-sequenced according to alternativeembodiments.

Features of any of the embodiments may be employed separately or incombination with any other feature(s) of the same or differentembodiments and the disclosure extends to and includes all sucharrangements whether or not described herein.

Other substitutions, modifications, changes and omissions may also bemade in the design, operating conditions and arrangement of the variousexemplary embodiments without departing from the scope of the inventionsdescribed herein.

What is claimed is:
 1. A mixing valve comprising: a mixing chamber; afirst flow control valve having a first flow control opening; and asecond flow control valve having a second flow control opening; whereinthe first and second flow control openings each have a diameter ofapproximately six millimeters and the mixing valve has a flowcoefficient of approximately 2.5 when both flow control valves are in amid-open position.
 2. The mixing valve of claim 1, wherein the mixingvalve has a flow rate of approximately 25 liters per minute at 1 barwhen both flow control valves are in the mid-open position.
 3. Themixing valve of claim 1, wherein the mixing valve has a housing with alength dimension, a width dimension, and a thickness dimension, andwherein the largest of these dimensions is no more than approximately 65millimeters.
 4. The mixing valve of claim 1, wherein each flow controlvalve comprises a valve member assembly configured such that, when inuse, fluid flowing through the valve exerts substantially no net forceon the valve member assembly.
 5. The mixing valve of claim 1, whereineach flow control valve is substantially force balanced with respect tothe force of fluid flowing through the flow control valve.
 6. The mixingvalve of claim 1, wherein each flow control valve comprises a valvemember assembly including two valve members spaced apart by a spool thatis controlled by a linear actuator, wherein each valve member isconfigured to engage a separate valve seat in a closed position for theassociated flow control valve.
 7. The mixing valve of claim 6, whereineach flow control valve comprises two openings into the mixing chamberand each valve member is associated with one of the two openings intothe mixer chamber.
 8. The mixing valve of claim 6, wherein one openingof the first flow control valve is located between the two valve membersof the first flow control valve when in the mid-open position.
 9. Themixing valve of claim 8, wherein the first of the two valve members ofthe first flow control valve is configured to be urged closed by fluidentering the first flow control opening and the second of the two valvemembers of the first flow control valve is configured to be urged openby the fluid entering the first valve flow control opening.
 10. Themixing valve of claim 1, wherein the mixing valve has a housing made ofa metallic material.
 11. The mixing valve of claim 1, wherein the mixingvalve has a size that allows it to be located within a spout of afaucet.
 12. A mixing valve comprising: a mixing chamber; a first flowcontrol valve having a first flow control opening; and a second flowcontrol valve having a second flow control opening; wherein the firstand second flow control openings each have a diameter of approximatelysix millimeters and the mixing valve has a flow rate of up toapproximately 25 liters per minute at approximately 1 bar when both flowcontrol valves are in a mid-open position.
 13. The mixing valve of claim12, wherein the mixing valve has a flow coefficient of up toapproximately 2.5 when both flow control valves are in the mid-openposition.
 14. The mixing valve of claim 12, wherein the mixing valve hasa housing with a length dimension, a width dimension, and a thicknessdimension, and wherein the largest of these dimensions is no more thanapproximately 65 millimeters.
 15. The mixing valve of claim 12, whereineach flow control valve comprises a valve member assembly configuredsuch that, when in use, fluid flowing through the valve exertssubstantially no net force on the valve member assembly.
 16. The mixingvalve of claim 12, wherein each flow control valve is substantiallyforce balanced with respect to the force of fluid flowing through theflow control valves.
 17. The mixing valve of claim 12, wherein each ofthe flow control valve comprises a valve member assembly including twovalve members spaced apart by a spool that is controlled by a linearactuator, wherein each of the two valve members are configured to engagea separate valve seat in a closed position for the associated flowcontrol valve.
 18. The mixing valve of claim 16, wherein each flowcontrol valve comprises two openings into the mixing chamber and the twovalve members of the valve member assemblies are each associated withone of the two openings into the mixer chamber.
 19. The mixing valve ofclaim 16, wherein one opening of the flow control valve is locatedbetween the two valve members of the first flow control valve when inthe mid-open position.
 20. The mixing valve of claim 18, wherein thefirst of the two valve members of the first flow control valve isconfigured to be urged closed by fluid entering the first flow controlopening and the second of the two valve members of the first flowcontrol valve is configured to be urged open by the fluid entering thefirst valve flow control opening.
 21. The mixing valve of claim 12,wherein the mixing valve has a housing made of a metallic material.